Crankshaft direct-connection extended-range oil cooling motor electric control system

Abstract

The invention discloses an electric control system of a crankshaft direct-connection range-extending oil cooling motor, and belongs to the technical field of range extender assemblies for new energy automobiles. The motor rotor support is used for installing a motor rotor, the motor rotor support fixes the motor rotor on an engine crankshaft through a plurality of motor rotor installation screws, the motor rotor support is arranged in the crankshaft direct connection oil cooling motor shell, and a gap between the crankshaft direct connection oil cooling motor shell and the motor rotor is sealed by a sealing oil seal. The crankshaft direct-connection oil-cooled motor shell is installed on a cylinder body gantry of a power input end engine, and a crankshaft direct-connection motor rear cover is installed on the crankshaft direct-connection oil-cooled motor shell. Compared with a traditional motor, the two-in-one integrated crankshaft direct-connection range-extending oil-cooled motor adopts a better cooling system scheme, effectively simplifies a motor and power assembly combination process scheme, improves the output efficiency of a motor system and a power assembly, and realizes effective cost reduction, low carbon and energy conservation; the device is economical and practical and can adapt to more vehicle types.

Description

Technical Field

[0001] The present invention belongs to the technical field of range extender assemblies for new energy vehicles, and in particular relates to an electronic control system for a crankshaft directly connected range extender oil-cooled motor. Background Art

[0002] The currently developed crankshaft direct-connected motor and electronic control systems for range extenders are mostly two-in-one crankshaft direct-connected water-cooled motor and electronic control solutions. The motor structure is simple and uses mature water channel welding technology solutions. Because the cooling effect of the water cooling solution is not as good as the oil cooling solution, the water-cooled length of the motor at the same power is longer than that of the oil-cooled motor, which greatly affects the space layout and increases the powertrain cost. Summary of the Invention

[0003] The purpose of the present invention is to provide a two-in-one highly integrated crankshaft direct-connected extended-range oil-cooled motor electronic control system, which can effectively improve the performance of the powertrain, increase the heat dissipation effect, effectively solve the above-mentioned problems, and at the same time take into account the cooling effect and space advantages.

[0004] The technical solution adopted by the present invention is: A crankshaft direct-connected oil-cooled motor electronic control system includes a sealing oil seal, a motor rotor bracket, a motor rotor mounting screw, a crankshaft direct-connected oil-cooled motor housing and a crankshaft direct-connected motor rear cover; the motor rotor bracket is used to install the motor rotor, and the motor rotor bracket fixes the motor rotor to the engine crankshaft by multiple motor rotor mounting screws. The motor rotor bracket is arranged inside the crankshaft direct-connected oil-cooled motor housing, and the gap between the crankshaft direct-connected oil-cooled motor housing and the motor rotor is sealed by a sealing oil seal. The crankshaft direct-connected oil-cooled motor housing is installed on the cylinder gantry of the engine at the power input end, and the crankshaft direct-connected oil-cooled motor housing is installed with the crankshaft direct-connected motor rear cover.

[0005] Compared with the prior art, the present invention has the following beneficial effects: Under the premise of changing the cooling method, the present invention adopts a rotor crankshaft direct connection solution to further compress the axial size of the range extender, solves many technical problems, and newly designs a large-size sealing oil seal to effectively solve the oil leakage problem.

[0006] The oil-cooled crankshaft direct-connect architecture reduces the use of components such as flywheels and torsional vibration dampers, reduces axial space, reduces the failure rate of product components, and greatly optimizes the axial size of the motor, which can better adapt to the vehicle cabin and achieve cost reduction and energy saving effects without affecting quality.

[0007] Compared with traditional motors, the two-in-one integrated crankshaft direct-connected extended-range oil-cooled motor of the present invention adopts a more optimal cooling system solution, effectively simplifies the motor and powertrain assembly process, improves the output efficiency of the motor system and powertrain, achieves effective cost reduction, low carbon and energy saving; it is economical and practical and can be adapted to more vehicle models. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 This is a schematic diagram of the installation of the crankshaft directly connected to the rotor portion of the present invention; Figure 2 It is an exploded view of the structure of the present invention; Figure 3 It is a schematic diagram of the cooling system of the present invention; Figure 4 It is a structural diagram of the cooling system of the present invention; Among them: 1. Sealing oil seal; 2. Motor rotor bracket; 3. Motor rotor mounting screws; 4. Crankshaft directly connected to oil-cooled motor housing; 5. Crankshaft directly connected to motor rear cover; 6. Mechanical oil pump; 7. Cooling oil pipe; 8. Oil cooler. DETAILED DESCRIPTION

[0009] In order to better understand the purpose, structure and function of the present invention, the present invention is further described in detail below with reference to the accompanying drawings.

[0010] Specifically, the present invention provides a novel architecture of an engine assembly and a crankshaft directly connected oil-cooled range-extending motor electronic control system, forming a highly integrated range-extending powertrain.

[0011] The present invention integrates a crankshaft directly connected oil-cooled motor and a generator controller, and can also simultaneously integrate multiple control systems.

[0012] like Figure 1 、 Figure 2 As shown, the present invention provides an electronic control system of a crankshaft direct-connected extended-range oil-cooled motor, comprising a sealing oil seal 1, a motor rotor bracket 2, a motor rotor mounting screw 3, a crankshaft direct-connected oil-cooled motor housing 4 and a crankshaft direct-connected motor rear cover 5; the motor rotor bracket 2 is used to mount the motor rotor, and the motor rotor bracket 2 fixes the motor rotor to the engine crankshaft through a plurality of motor rotor mounting screws 3, the motor rotor bracket 2 is arranged inside the crankshaft direct-connected oil-cooled motor housing 4, and the gap between the crankshaft direct-connected oil-cooled motor housing 4 and the motor rotor is sealed by the sealing oil seal 1, the crankshaft direct-connected oil-cooled motor housing 4 is mounted on the cylinder gantry of the engine at the power input end, and the crankshaft direct-connected oil-cooled motor housing 4 is mounted with a crankshaft direct-connected motor rear cover 5.

[0013] Figure 1 In the exploded view, the large-size sealing oil seal 1 is pre-installed on the front end of the motor rotor bracket 2. The motor rotor bracket 2 fixes the motor rotor to the engine crankshaft through multiple motor rotor mounting screws 3. Figure 2In the exploded view, the crankshaft direct-connected oil-cooled motor housing 4 includes a crankshaft direct-connected oil-cooled motor stator fixed inside by screws, a crankshaft direct-connected oil-cooled motor rotor (including a motor rotor bracket 2) fixed by a stopper and a motor rotor sealing oil seal 1, a cooling oil pipe 7 fixed by screws, an oil cooler 8 and other components.

[0014] First, apply an even coating of sealing silicone to the engine flange. Then, install the crankshaft direct-connected oil-cooled motor housing 4 onto the engine cylinder gantry at the power input end using a single set of mounting screws. Open the crankshaft direct-connected motor rear cover 5 and secure the motor rotor mounting screws 3 to the engine crankshaft at the power input end through the motor rotor bracket 2 inside the crankshaft direct-connected oil-cooled motor housing 4. Finally, apply an even coating of sealing silicone to the rear end of the crankshaft direct-connected oil-cooled motor housing 4 and secure the crankshaft direct-connected oil-cooled motor housing 4 with screws. This completes the installation.

[0015] The inner diameter of the sealing oil seal 1 is 89±mm and the outer diameter is 96mm~100mm. It is a large-sized oil seal.

[0016] The motor rotor mounting screws 3 are provided with solid anaerobic sealant and screw sealing rubber rings.

[0017] like Figure 3 、 Figure 4 As shown, the electronic control structure of the oil-cooled motor is newly designed from the original cooling scheme with a water channel in the shell to an oil-cooled motor scheme that eliminates the water channel and uses a mechanical oil pump 6 to spray oil and a cooling oil pipe 7 to spray. The cooling oil pipe 7 and the mechanical oil pump 6 that runs with the motor rotor are newly added to the structure. The specific structure is: the motor rotor is connected to the mechanical oil pump 6, and a circulation pipeline is formed between the mechanical oil pump 6 and the oil cooler 8 through the cooling oil pipe 7. The cooling oil pipe 7 located above the motor oil pool has evenly distributed small holes and can evenly spray the cooling oil onto the motor stator. The oil channel and end outlet of the other cooling oil pipe 7 in the motor rotor evenly cool the motor rotor with the centrifugal force of the motor rotation.

[0018] The motor rotor rotates to drive the mechanical oil pump 6, which draws the motor-specific cooling oil in the oil pool into the motor cooling oil pipe 7. The cooling oil pipe 7 above the motor oil pool has evenly distributed small holes. The cooling oil flows out of the small holes under the action of gravity and internal pressure, and the outflowing cooling oil returns to the oil pool, repeating the cycle to cool the motor.

[0019] Through a more effective cooling solution, the material consumption of the motor under the same power is reduced to achieve effective cost reduction. In daily use, the oil leakage of the crankshaft direct connection part is taken into consideration. A special sealing oil seal 1 is specially designed and a special structure of motor rotor mounting screws 3 are used to effectively solve the concern of oil leakage, greatly compress the axial dimension of the range extender assembly, and improve the scalability of the range extender solution.

[0020] A controller is integrated above the crankshaft direct-connected oil-cooled motor housing 4 or on the crankshaft direct-connected motor rear cover 5 , and the controller uses an independent cooling water circuit to dissipate heat for the IGBT.

[0021] This structural connection method of the present invention features a direct oil-cooled crankshaft connection, meeting space requirements. The main structure comprises a specially designed oil seal 1, specially constructed motor rotor mounting screws 3, a crankshaft directly connected to the oil-cooled motor housing 4, a cooling oil pipe 7 and rotor center oil passage, a range extender motor stator, a range extender motor rotor, a mechanical oil pump 6 (an electronic oil pump can be used for higher power requirements), an oil cooler 8, an oil drain plug, and an integrated generator controller (optionally, an integrated ECU controller). The following lists the main structure and functions of a preferred embodiment.

[0022] Inside the cavity of the crankshaft direct-connected oil-cooled motor housing 4, a newly designed large-sized sealing oil seal 1 at the crankshaft direct-connected range-extended oil-cooled protective oil seal can effectively seal the gap between the crankshaft direct-connected range-extended motor rotor and the crankshaft direct-connected oil-cooled motor housing 4. Special motor rotor mounting screws 3 with sealing effect are used. Because the engine and the crankshaft direct-connected oil-cooled motor electronic control side adopt the oil cooling solution, and the engine side adopts the oil cooling method, the two sides use different cooling media and different pressures in the wall. Therefore, in order to ensure the sealing effect on both sides, the sealing of the two cavities must be ensured. The engine side is sealed by the crankshaft rear oil seal, and the crankshaft direct-connected motor is sealed by the large-sized sealing oil seal 1. The stator and rotor of the crankshaft direct-connected oil-cooled motor are critical components of the motor and directly contribute to its power generation. The stator coils must be neatly painted and tightly arranged. They are secured within the inner cavity of the crankshaft direct-connected oil-cooled motor housing 4 with oil-proof screws. To ensure performance, the air gap between the motor rotor and stator is relatively small. Therefore, the rotor and stator must be installed with an error within 0.02mm.

[0023] The range extender utilizes an oil cooling system. Cooling oil is evenly sprayed onto the range extender motor stator through cooling oil pipe 7, while another oil path flows through the motor rotor's internal oil passage and outlet, cooling the motor rotor evenly due to the centrifugal force of the motor's rotation. An oil sump is located inside the range extender motor to collect the circulating cooling medium. The medium then passes through a high-density oil filter and is pumped by mechanical oil pump 6 to the oil cooler 8 for recirculation and cooling, completing a cooling cycle.

[0024] The integrated control system is designed as a crankshaft direct-connected extended-range oil-cooled motor integrated generator controller system. The controller uses an independent cooling water circuit to dissipate heat for the IGBT. The integrated controller can be configured to be integrated with the upper or rear end cover of the crankshaft direct-connected oil-cooled motor, which can be adjusted according to the vehicle cabin layout.

[0025] It will be understood that the present invention is described by way of some embodiments, and it will be appreciated by those skilled in the art that various changes or equivalent substitutions may be made to these features and embodiments without departing from the spirit and scope of the present invention. In addition, under the teachings of the present invention, these features and embodiments may be modified to adapt to specific circumstances and materials without departing from the spirit and scope of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are intended to be protected by the present invention.

Claims

1. A crankshaft directly connected range extender oil-cooled motor electronic control system, characterized by: The invention comprises a sealing oil seal (1), a motor rotor bracket (2), a motor rotor mounting screw (3), a crankshaft directly connected oil-cooled motor housing (4) and a crankshaft directly connected motor rear cover (5); the motor rotor bracket (2) is used to mount the motor rotor, the motor rotor bracket (2) fixes the motor rotor to the engine crankshaft through a plurality of motor rotor mounting screws (3), the motor rotor bracket (2) is arranged inside the crankshaft directly connected oil-cooled motor housing (4), the gap between the crankshaft directly connected oil-cooled motor housing (4) and the motor rotor is sealed by the sealing oil seal (1), the crankshaft directly connected oil-cooled motor housing (4) is mounted on the cylinder gantry of the engine at the power input end, and the crankshaft directly connected oil-cooled motor rear cover (5) is mounted on the crankshaft directly connected oil-cooled motor housing (4).

2. The crankshaft directly connected range extender oil-cooled motor electronic control system according to claim 1, characterized in that: The inner diameter of the sealing oil seal (1) is 89±mm, and the outer diameter is 96mm~100mm.

3. The crankshaft direct-connected range-extending oil-cooled motor electronic control system according to claim 1, characterized in that: The motor rotor mounting screws (3) are provided with solid anaerobic sealant and screw sealing rubber rings.

4. The crankshaft directly connected range extender oil-cooled motor electronic control system according to claim 1, characterized in that: The cooling system provided on the crankshaft direct-connected extended-range oil-cooled motor electronic control system is as follows: the motor rotor is connected to a mechanical oil pump (6); a cooling oil pipe (7) is formed between the mechanical oil pump (6) and the oil cooler (8); the cooling oil pipe (7) located above the motor oil pool has evenly distributed small holes and can evenly spray the cooling oil onto the motor stator; the oil path and the end outlet of the other cooling oil pipe (7) in the motor rotor evenly cool the motor rotor as the centrifugal force of the motor rotates.

5. The crankshaft directly connected range extender oil-cooled motor electronic control system according to claim 1, characterized in that: A controller is integrated above the crankshaft directly connected oil-cooled motor housing (4) or on the crankshaft directly connected motor rear cover (5), and the controller uses an independent cooling water circuit to dissipate heat for the IGBT.

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